Before our third child, Alexander, was born, we wanted to really make his room unique for him. We didn't want to spend a lot, so we considered more of a rustic look, and I decided I would build much of what we wanted in his room. One of these items included a rustic pallet wood sign with a modern flair to it.
I had made a similar sign to go over our laundry room previously, and had bought a vinyl stencil from an etsy shop to make that one. This time, I wanted to try my hand at creating my own stencil.
TOOLS & MATERIALS
(using these affiliate links gives a portion of anything you buy on Amazon to me, at no cost to you)
Table Saw - http://amzn.to/2s8JpAD
Circular Saw - http://amzn.to/2sZeAdY
Nail Gun - http://amzn.to/2s8YbYa
Air Compressor - http://amzn.to/2s8YbYa
Wood Glue - http://amzn.to/2s93w1K
Jigsaw - http://amzn.to/2s8YsdE
Painter's Tape - http://amzn.to/2sInv4m
Spray Lacquer - http://amzn.to/2sZ6lig
X-Acto Knife - http://amzn.to/2r6J9Sp
Spray Paint (buy locally)
Break Down Pallets
There are many ways to break down pallets into usable materials. I'm not going to go into that here, but just search out "how to break down a pallet" and you'll find plenty. For these particular pallet boards, they still have the nail holes intact.
I have learned from past projects using pallet wood that one of the biggest frustrations is that nothing is the same size. Therefore, I used my jointing jig to create one straight side on the board. Then, I flipped it around and ripped the other side off. I did this to all of the boards, and made them all the same width. This would help me later when I needed to develop the pattern.
Paint & Stain
I wanted three distinct colors for this sign, so I decided on black, gray and natural. For the black, I used some cheap spray paint. (HINT: don't pay $4 for a nice can or spray paint for something like this. Just buy the cheap stuff for about $.99...it will work just fine)
For the gray, I used a driftwood stain, because I wanted to see the wood grain show through a bit. This turned out nice, and I have since used this stain quite a few times.
Prepare whatever you're going to use to nail the pallet wood onto. I'm using a scrap piece of 3/4" plywood I had lying around. I am using a method that I saw Bob Clagett from I Like To Make Stuff do. He cut out some of the plywood, cut a French cleat into it and attached it to the board again. It will act like an integrated French cleat.